Question about Datamax I-4208 Thermal Label Printer

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I-4208 DataMax printer

When I turn on the printer it comes up with "position fault".
If I hit the feed bootom it comes up with "top og form error".

I have reset the printer and tried to calibrate the sensor but it comes up with "faulty sensor".

Is this something I can clear out of the machine?

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  • leeann980 Jan 14, 2009

    I have the same thing happening but....The tags we print are beautiful and no issues at all but when we go to print labels we are getting tof of form fault or position fault and if we do get it to calibrate it only does like after of the job and then we get top of form fault again.....any ideas?

  • sandlizardz Apr 24, 2009

    You can clean the senosr. It move and you can adjust and clean it manually. I have the same problem right now on our 3rd I 4208. It will print but all the labels are shifted to the right unlike when printing to our 2 other I 4208's. I am bound and determined to get it working right before the end of today and I will post here again with my results.

  • sandlizardz Apr 24, 2009

    You can clean the senosr. It move and you can adjust and clean it manually. I have the same problem right now on our 3rd I 4208. It will print but all the labels are shifted to the right unlike when printing to our 2 other I 4208's. I am bound and determined to get it working right before the end of today and I will post here again with my results.


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We had the same error after labels got wrapped around the feed roller. When we were called to investigate the problem, the fault error was there. After 2 1/2 hours of troubleshooting both on the printer and online we came across this page. I took the roll of labels out, cleaned the media sensor and re-threaded the labels. Well, that didn't work too well as I still had the same error. Since we have 2 thermals setting side-by-side, I opened up both hoods and noticed that the "green" slider just beneath the sensor was slid all the way in. On the other printer however, the slider was slid out until a white etched line was at the tappered endpoint of the sensor. I slid out the other printer that had my error, hit the feed button, and whaaa-laaa, the error disappeared. There are some minor distance feed that we have to reset, but it is up and running! I hope this may help you out in your situation too.

Posted on Jun 12, 2009

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You have to do some disassembling on the printer, open the door to reveal the ribbons, and on the top side you will find two screws, take those out and one ones on the bottom side of that same panel; lift the door and you will have the internal mechanism. There is a cable data/ribbon which connects to the green slider, take it out and check what side the pins were connected to. Now, with a screwdriver, take out the screw that connects the green slider to the printer; there is a metal rod which slides out to the other side CAREFULLY take out the green slider and disassemble the pegs to reveal the sensor, use isopropyl alcohol on that and dry it out, same with the metal rod, making sure there is no gunk on it.Reassemble, load ribbon and labels and calibrate. This always works!

Posted on Sep 21, 2009

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Despues de limpiar el sensor y colocarlo en la posicion correcta, puedes intentar ejecutar el procedimiento de calibracion en el menu de la impresora. Tambien puedes intentar una calibracion rapida asi: presiona la tecla FEED y mantenla apretada, la etiqueta avanzara con pausas, cuenta 3 o 4 pausas y suelta el boton. Calibration Complete aparecera en la pantalla de la impresora. Si no se calibra, vuelve a repetir el procedimiento. After cleaning the sensor and place it in the correct position, you can try running the calibration procedure in the menu on the printer. You can also try a quick calibration as follows: press the FEED and keep down, to advance the label breaks, count 3 or 4 breaks and release the button. Calibration Complete screen will appear in the printer. If it is not calibrated, repeats the procedure.

Posted on Jun 10, 2009

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I am sorry to tell ya but you have a bad Media Sensor. They are not too hard to replace once you get the part so if you are looking to do it yourself I would say it can take about 20 minutes as long as you are patient. Good Luck.

Posted on Nov 04, 2008

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